From the Silicon Pore Optics (SPO) of NewAthena to the Einstein Telescope, cosine’s proprietary bonding techniques are enabling the next generation of space and terrestrial instrumentation.
Originally perfected for SPO, our bonding expertise in combination with production capabilities has evolved into range of services that support high-precision projects. Today, these are used for flagship missions like ESA’s X-ray telescope NewAthena or the Einstein Telescope, a next generation gravitational wave detector. cosine is now expanding these capabilities to fabricate large-scale mirrors and specialised components for both academic and industrial customer.
Seamless integration capabilities
cosine’s approach focuses on two primary bonding methodologies, selected based on the specific mechanical and chemical requirements of the application.
Direct bonding is ideal for surfaces with extreme flatness and low roughness. By carefully activating the surfaces, we achieve a molecular bond without the need for intermediary adhesives.
Hydroxide Catalysis Bonding (HCB), is a more flexible technique that allows for high-strength precision bonding even when surface requirements are less rigid.
“To bond surfaces successfully requires a delicate balance of variables,” explains Dr. Marloes Bistervels, Senior-Scientist at cosine. “If you have the right material, the right surface energy, roughness, flatness, as well as, crucially, the right cleanliness, you can achieve an incredibly strong bond. At our headquarters in Sassenheim, we facilitate this through our extensive suits of specialised equipment, located within more than 1,000 m² of ISO 5 to 7 cleanrooms.”
A full-cycle bonding pipeline
“Bonding is only as effective as the alignment that precedes it. We provide sub-micron alignment and utilize thermal treatments in furnaces reaching up to 1200 °C. This allows us to tailor mechanical properties for environments ranging from deep space to cryogenic detectors,” continues Dr. Bistervels.
cosine offers a comprehensive “end-to-end” service to ensure the highest success rates for complex assemblies:
• Clean: Specialized cleaning of samples in our ISO-certified cleanrooms.
• Activate: Surface preparation to maximize bonding energy.
• Align: Sub-micron positioning for complex geometries.
• Strengthen: Thermal processing to solidify the molecular interface.
• Test: Rigorous validation of bond strength and quality.
Whether for world-class observatories or small-scale tech innovations, cosine’s fusion of equipment and experience ensures that complex systems stay together.
